Formic Acid Blown EPIC Foams

Patent Title: ISOCYANATE-BASED TEMPERATURE-RESISTANT FOAMS WITH HIGH FLAME RESISTANCE

 Number/Link: WO2016/131874

Applicant/Assignee: BASF, Covestro

Publication date: 25-08-2016

Gist”:  One shot rigid isocyanate-epoxy foams blown with formic acid

Why it is interesting: This is the first in a series of (at least) 3 patent applications apparently resulting from a cooperation between BASF and Covestro on epoxy-isocyanate (“EPIC”) foams.  The other applications are WO2016/131878 and WO2016/131880 published on the same date. More publications may follow.
The current invention is about temperature-resistant foams with reportedly very high mechanical properties prepared form a one-shot system comprising a (pref.) high functional MDI, a (pref.) bisphenol-A or bisphenol-F polyglycidylether, at least one reactive amine catalyst and a blowing agent comprising formic acid. The ratio of iso to epoxy groups is (pref.) 3:1 to 15:1. The resulting materials are post-cured at 200°C. The foams contain no, or very little, urethane or urea groups and are said to be especially useful in laminates a.o.  In the examples foams with densities of 25-35 kg/m³ with a thermal conductivity as low as 20 mW/mK are shown.

Bisphenol-F diglycidylether

Bisphenol-F diglycidylether

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PPE-Filled Rigid Foams

Title: RIGID FOAM AND ASSOCIATED ARTICLE AND METHOD

 Number/Link: WO2015/012989

Applicant/Assignee: SABIC

Publication date: 29-01-2015

Gist”: Rigid polyurethane foams containing polyphenylene ether particles

Why it is interesting: This invention is about rigid PU or PIR (polyisocyanurate) foams containing up to 25% w/w on the total composition of poly(2,6-dimethyl-1,4-phenylenether) particles.  The particles have a mean particle size of about 6 µm and are prepared by jet milling a commercial grade of PPE powder. The resulting foams are said to have reduced flammability and water absorption.  This is the second patent application that SABIC files on PPE-PU hybrids or combinations.  An interesting development but it is hard to believe that these ideas are practical and economical.

poly(2,6-dimethyl-1,4-phenyleneether)

poly(2,6-dimethyl-1,4-phenylene ether)

A Simple Way to Make Nonflammable Flexible Foams

Title: METHOD FOR PRODUCING FLAME-PROTECTED POLYURETHANE FOAMS HAVING LOW BULK DENSITIES

 Number/Link: WO2013174745  (German)

Applicant/Assignee: Bayer

Publication date: 28-11-2013

Gist”: Low density flex foam is impregnated with water glass

Why it is interesting: A flexible slabstock foam with a density of about 15 kg/m³ or less is submerged in a solution of amorphous water-slouble silicate, preferably a  Na-silicate, then compressed in a roller mill and dried.  The resulting foam has a (much) higher density but also a much improved flame resistance.  In an example an 11.6 kg/m³ TDI slab foam resulted in a 27.3 kg/m³ density foam after impregnation and drying.  A simple and workable idea but I doubt if it is patentable.

Sodium silicate

Sodium silicate

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